FEATURED PROJECT

P e t r o c h e m i c a l Industries Design Equipment & Parts Manufactring Co.

Mechanical Design & Fabrication of Sulfur Recovery Unit Sulfur Condensers & Reactors

Overview:Pidemco was awarded the 3 reactors and 2 sulfur condensers of Sulfur Recover Unit of area 200 NGL3200 plant. Our client was Tehran Raymand Co. as EP contrac-tor of the project. the whole tonnage of the equipments was about 110 tons and it was delivered within project schedule. Our work scope was mechanical design, fabri-cation and qurantee of these equipment.

Project controlOur project control team prepared time schedule, VPIS and WBS documents and planned and monitored project tasks us-ing MS Project software. we informed our client of project progress by biweekly re-ports.

ProcurmentProject raw materials should have com-plied to Nace MR 0175 and client’s restrict requirements. The plates were supplied from german, tubes and forge material form south korean, Piping material from japanese and fittings from western europ sources. The commercial department of Pidemco were involved in sourcing, pro-curment, shippment and clearance of raw materials. dished heads were outsourced to Irainian head manufacturers.

EngineeringMechanical design was according to ASME SEC. VIII DIV.1 standard. TEMA standard were considered in design and fabrication of sulfur condenseres. Wind and Siesmic calculations were done based on UBC.

Project SummaryYear:2015

Duration:10 Months

Client:Tehran Raymand Co.

Owner:N.I.O.C

Licensor:Prosernat

Equipment Type:Sulfur Condenser & Reactor

Quantity:5

Weight:110 Tons Total

Work Scope:Mechanical design, fabrication and refractory lining

Project Tchnical information:Item Sulfur condenser (E-600-

102/202) Reactor (R-600-101/201) Reactor (R-600-002)

Construction Material Carbon Steel (Nace) Carbon Steel (Nace) Carbon Steel (Nace)Design Code ASME SEC.VIII Div.1 ASME SEC.VIII Div.1 ASME SEC.VIII Div.1Material Code ASME ASME ASMEService Integrated Sulfur Condenser 1th & 2ed stage Reactor Hydrogenation ReactorDesign Pressure 7 barg 3.5 barg 3.5 bargDesign Temperature 350 C 350 C 300 CMedium Process Gas Process Gas Process GasID * TL to TL (mm) 1900 X 3700 2450 X 5600 2500 X 6000

EngineeringSupply of Raw Material

FabricationHYD. Test & Final Inspection

Month

1Month

2Month

3Month

4Month

5Month

6Month

7Month

8Month

9Month

10

Find about Pidemco at : www.pidemco.comContact Pidemco:info@pidemco.com+98 21 468 30200~209No.33, Sanat Yekom St., Enghelab Blvd., Shahr -e-Ghods, 20th km Tehran-Karaj Old Road, Tehran, Iran

PVElite software was used for code calcu-lations. To calculate the local stresses on nozzle neck WRC 107 were considered and for nozzles out scope of this bulltin, FEA claculations were done based on ASME SEC VIII DIV.2 part 5 linear method using Noz-zlePro software.

Mechanical design of sulfur condenser Tubesheets are a very critical issue as they undergo great thermal stresses during op-eration upset conditions. Special drain conections were devised to facilitate cleaning of sulfur choke up.

Reactors Internal supports, seperation plates and lugs and details were specified and their integrity were checked by design by analysis method of ASME SEC. VIII DIV2 Part 5.

FabricationTubes were Light expanded after welding away from tube to tubesheet welds. Since tubes were thick in sulfur condensers low tube expansion ratio were considered as it may brought tubesheet to undergo plastic deformation and loss of ductility around tubes. Low sulfur electrodes were imple-mented and hardness of weld metal and HAZ was ensured not to be over 200 HB. Welding were done in a way that ensured least welding heat input. Tubesheet un-tubed area lined with refractory in order to reduce the thermal shock in abnormal conditions during operation. Refractory application is vital to equipment lifetime. refractory anchor size and positioning was designed accurately so to prevent them-from cracking the refractory. . Refractory lining thickness 75mm is considered to prevent elemental sulfur contacting metall surface in reactors. The whole equipment were put in furnace and PWHT were con-ducted to eleminate any residule stresses left during welding and forming operations

Quality ControlVarious procedures were prepared and imposed fro conducting manufacturing ac-tivities.100% RT were conidered to ensure no defect welds. Tube to tubesheet welds, Nozzle to shall welds were checked with UT. After PWHT all welds were NDT tested befor hydrotest once more.

Project Features:Part Details of Reactors

design of Sulfur condeners Tubesheet

Manufacturing equipment for Sour service according to NACE MR 0175

Refractory Lining of Reactors

Sulfur condenser drain connec-tions